Knitted glove with modified variable plating having a reinforced region

ABSTRACT

A knitted glove and a method of making a knitted glove. The knitted glove comprising a plurality of glove components wherein at least one section of at least one of the components in the plurality of components comprises two yarns knitted simultaneously forming a plated structure and at least one reinforced region formed on the glove having at least three stitch courses.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 12/430,048, filed Apr. 24, 2009, which is a continuation-in-part of U.S. Ser. No. 12/209,529 filed on Sep. 12, 2008 now U.S. Pat. No. 7,555,921, which is a continuation-in-part of U.S. Ser. No. 11/444,806 filed on Jun. 1, 2006 now U.S. Pat. No. 7,434,422, which is a continuation-in-part of U.S. Ser. No. 11/181,064, filed Jul. 13, 2005, now U.S. Pat. No. 7,213,419, which is a continuation-in-part of application Ser. No. 10/892,763, filed Jul. 16, 2004, now U.S. Pat. No. 6,962,064. Each of the aforementioned related patent applications are herein incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the present invention generally relate to knitted gloves. More specifically, embodiments of the invention relate to modified variable plating as used in knitted gloves, knitted glove liners, and methods of making knitted gloves or knitted glove liners.

2. Description of the Related Art

Knitted gloves are commonly used in handling and light assembly conditions. Knitted gloves used for these purposes are currently made using flat knitting machines that use a number of needles in the form of a needle array and a single or multiple yarns to knit the gloves. Among other mechanism and controls, flat knitting machines include a yarn feeding apparatus and a stitch control system. In general, the stitch control system includes the necessary hardware and proportional-integral-derivative (PID) controller to control the stitch dimension or loop size. While the yarn feeding apparatus minimizes the fluctuations in knitting yarn tension. A glove is generally knitted as a collection of components, e.g., eight components. The eight glove components include one component for each of the five fingers, two components for the palm including an upper section and a lower section, and one component for the wrist area (cuff). All of the sections are cylinders or conical sections that join to each other fashioning the general anatomical shape of a hand. Conventional knitting processes use the knitting machine to knit each of the areas in a particular sequence, generally one finger at a time, beginning with the pinky finger and continuing on through the ring finger and middle finger to the forefinger. After each finger is knitted using only selected needles in the needle array, the knitting process for the completed finger is stopped, and yarn is cut and bound. The knitted finger is held by holders and weighted down by sinkers. The remaining fingers are knitted sequentially, one at a time, using a different set of needles in the needle array. When all four fingers are knitted in this fashion, the knitting machine then knits the upper section of the palm, picking stitches from each of the previously knit four fingers. After knitting an appropriate length of upper palm, the thumb portion is initiated, using a separate set of needles in the needle array, and the lower section of the palm is knitted using all of the needles in the needle array. Finally, the knitting machine knits the wrist component to the desired length. Glove components are joined together, after each component is knitted, using one or two overlap stitch courses. Overlap stitch courses proceed from one glove component to the next to interconnect the components.

The knitting stitches used at the fingertips are generally tighter than the stitches used elsewhere in the glove to improve the strength of the glove in the fingertips area, where more pressure is likely to be applied during use. Depending on the size of the needles used and the denier of the yarn, a certain number of courses are used to create each of the eight components of the glove. The finer the gauge of needle used, the higher the number of courses for each component to create the same size of a finished glove. Changing needles or the denier of a yarn is extremely difficult in a continuous process and generally a continuous yarn of pre-selected denier and a corresponding needle size are commercially used. While this standardization in needle size and number of courses permits the manufacturing of a glove or liner with a standard shape, that shape does not accommodate variations in size.

In knitting, a plated structure has two loops in each stitch The two loops results from the simultaneous feeding of two yarns to the needles of the knitting machines. The loops are positioned such that one yarn is on one side of the stitch and the other yarn is on the other side of the stitch. A knitted glove or liner may be comprised of a straight plated structure. That is, it may have one type yarn on the inside and another type yarn plated on the outside. For example, a glove may be knitted such that it has a yarn which has a soft comfortable feel on the inside and plated with a spandex type yarn on the outside to provide stretch. Such knitted gloves or liners are generally straight, i.e., fully plated with a particular using a varying number of stitch courses. Straight plated gloves or liners are relatively heavy as compared to a glove knitted with a single yarn. Additionally, the use of straight plating yields a narrow circumference for each of the glove's finger components. If the glove is coated (e.g., dipped in latex, nitrile or polyurethane) to provide a protective, high grip surface, the narrow circumference leads to a relative heavy penetration of coating during the coating process, especially in the finger crotch areas. Such penetration can make the gloves uncomfortable to wear.

Therefore, there is a need in the art for a knitted glove having reinforced regions, e.g., finger crotch areas to reduce coating penetration during the coating process and provide other benefits.

SUMMARY OF THE INVENTION

Embodiments of the present invention generally relate to a knitted glove and a method of making a knitted glove. The knitted glove comprising a plurality of glove components wherein at least one section of at least one of the components in the plurality of components comprises two yarns knitted simultaneously forming a plated structure and at least one reinforced region formed on the glove having at least three stitch courses.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

FIG. 1 shows a glove according to an embodiment of the present invention.

FIG. 2 illustrates an embodiment of varying stitch dimension using a stitch setup wherein the needle penetration determines the length of yarn included in the stitch.

FIG. 3 illustrates an embodiment of varying stitch dimension using an different stitch setup wherein the needle penetration is larger than the penetration in FIG. 2.

FIG. 4 shows an embodiment of the stitch dimension wherein the computer controls the yarn feeding roller and the tension in the yarn between the pinch roller and the knitting head.

FIG. 5 shows a schematic representation of two needle beds used to form reinforced regions of one embodiment of the invention.

FIG. 6 shows a glove according to an embodiment of the present invention having nine components.

While the invention is described herein by way of example using several embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modification, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims. The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include,” “including,” and “includes” mean including, but not limited to. The word “glove” means glove or glove liner.

DETAILED DESCRIPTION

Embodiments of the present invention comprise a knitted glove with modified variable plating for creating select reinforced regions on the glove. FIG. 1 depicts a glove 200 according to one embodiment of the present invention. This glove 200 includes nineteen total sections of the glove, including three sections for each of the finger components 210, 212, 214, and 216 and thumb 218 of the glove, three palm sections 204, 206, and 208 and one wrist section 202. Each of the fingers 210, 212, 214, 216 and 218 is knit according to three separate instructions for the knitting machine to create these three distinct areas designed to conform to the shape of fingers. These three sections are shown in FIG. 1 as sections 250, 252, and 254 for the pinky finger 210; sections 244, 246, and 248 for the ring finger 212; sections 238, 240 and 242 for the middle finger 214; sections 232, 234, and 235 for the forefinger 216; and sections 220, 222, and 224 for the thumb 218.

One embodiment of the present invention incorporates extra yarn in the finger crotch areas 260, 262, 264, 266 by knitting a modified variable plated structure in those areas comprising at least three stitch courses. Specifically, the number of overlap courses in the figure crotch is increased to at least three to create a reinforced region. Generally, no more than two stitch courses are used as overlap stitch courses in joining the various components of the glove together. If the glove is coated, the extra material minimizes coating penetration in the finger crotches where penetration is typically heavy relative to the other sections of the glove. Whether the glove is coded or not, the extra yarn adds reinforcement to the finger crotch area adding strength to the finger crotches. In some embodiments, to compensate for the additional weight of the extra stitches, various other sections of the glove may be knitted using a single yarn, e.g., not plated.

The glove 200 of this invention can be knit on a knitting machine and requires programming of the machine for each of the nineteen sections. For example, the glove 200 can be made according to the specifications provided in Table 1. Each of the components is indicated, and the sections that match FIG. 1 are shown. Note that the courses begin with 1 for each component and continue through the sections. The stitch setup here shows a number, which indicates how deep the knitting needle penetrates. A lower number indicates less needle penetration, while a larger number indicates that the needle penetrates deeper. For example, in component 1, which is the pinky finger, the first course has a knitting needle penetration depth of 37 in course 1 and increases gradually in a linear fashion to a knitting needle penetration depth of 39 at course 22. This means that course 1 is tighter to stretch than course 22, and the pinky finger is draped by the glove with the finger edge tight against the glove. The second section of component 1 continues seamlessly with the same stitch setup of 39, maintaining the depth of penetration of the knitting needle.

TABLE 1 STITCH SECTION IN COMPONENT SETUP COURSES FIG. 1 1 37-39  1-22 250 39 23-58 252 39-37 59-88 254 2 37-39  1-32 244 39 33-72 246 39-37  73-116 248 3 37-39  1-32 238 39 33-72 240 39-37  73-126 242 4 37-39  1-32 232 39 33-72 234 39-37  73-116 235 5 37  1-56 208 6 37-39  1-32 220 39 33-69 222 39-37  65-100 224 7 37  1-20 206 36-22 21-70 204 8 37  1-72 202

This specification in Table 1 can be used on a SFG knitting machine available from Shima Seiki Mfg., Ltd. based in Wakayama, Japan to create a size 9 glove. The information for the stitch setup and the number of courses are entered into the knitting machine's operation system using a keypad and LED display. Adjustments can be made to the specifications in Table 1 to create gloves of different sizes. The gloves can be knit from different compositions of yarn, including cotton, nylon fibers, water-soluble fibers, such as polyvinyl alcohol, or other fibers that can be used on a knitting machine, such as polyester or high-strength synthetic fibers, such as aramid, polyethylene, and liquid crystal polymer. The yarns used to knit the gloves can be spun yarns, textured filament yarns, or multi-component composite yarns.

FIG. 2 illustrates at 30 a stitch knitted with a smaller stitch setup number. The knitting needle 35 penetrates to a smaller extent, including a smaller loop of yarn 36 in the stitch, providing limited stretch capability.

FIG. 3 illustrates at 38 a stitch knitted with a larger stitch setup number. The knitting needle 35 penetrates to a larger extent, including a larger loop of yarn 36 in the stitch, providing enhanced stretch capability.

FIG. 4 illustrates at 40 a yarn 41 from a conical spool 42 fed through a pinch roller 43 and yarn feed roller 44. The yarn 41 is supplied to the knitting head 45 through a tension control device comprising a arm 46 attached to a spiral spring 47 which is connected to a computer controlled stepper motor 48. The rotation of the stepper motor shaft 49 increases the tension provided by the spiral spring 47, enhancing the tension in the yarn in the segment between the pinch roller 43 and knitting head 45. This variation in tension, generated under computer control, incorporates a higher level of tension within the stitch, limiting its stretch capability. The dimension of the stitch is independently controlled by the feed roller 44, which is also controlled by the computer.

FIG. 5 is a schematic representation of a pair of needle beds 500 (upper bed 502 and lower bed 504). The upper bed 502 is holding the previously completed course 506, while the lower bed 504 is operating to add the additional stitches in the reinforced region 508. To facilitate the reinforcement, a select number of needles 510 (e.g., four) are used to add an additional stitch course 510 in the region 508 i.e., in one embodiment, three stitch courses 510 ₁, 510 ₂, 510 ₃ form the reinforcement in region 510. The additional course is added by activating the plait feeder and adding an additional yarn to overlap and reinforce the region 508. In this manner, the glove is reinforced in the selected region 508.

The knitted variable stitch dimensions in the glove 200 allow the alteration of stitch dimension within a larger number of finger and palm sections than would be found in a standard glove having eight components. This increased number of sections benefits the glove by improving the degree to which it conforms to the shape of the hand, creating a better fit. In turn, this better fit provides increased dexterity and grip as well as increased long-term comfort in wearing the glove. In the embodiments of the present invention, stitch dimensions can be increased in areas such as knuckles, which would require greater glove flexibility as fingers move and overlapping stitches can be used in the finger crotches or elsewhere. Additionally, additional courses may be added to the reinforced regions to strengthen these regions.

Knitted stitch dimensions can be used to eliminate additional manufacturing steps that would be required in, for example, the use of heat or water to shrink gloves or liners to fit a particular hand size. This saves both money and time in the manufacturing process and does not require unique times, temperatures, or pressures. It also produces a more consistent product than one relying on difficult-to-control steps, such as heat or tumbling.

The knitted gloves forming embodiments of this invention, once finished, also can be coated either on the outside or inside with a coating, such as natural rubber latex or synthetic rubber latex, as well as other elastomeric polymer coatings. The coating can be applied by dipping the knitted glove into the coating material or by spraying the coating onto the glove. Coating the knitted gloves can improve the grip of the glove in handling dry and oily items when the coating is on the outside of the glove. The addition of a coating to the knitted layer can also improve the quality of the glove as an insulator. By having the finger crotches reinforced with overlapping courses, there is substantially less penetration of coating material into the reinforced regions as compared to similar areas without reinforcement on standard gloves. In some embodiments, none of the coating material penetrates through the reinforced regions.

FIG. 6 shows a glove 600 according to one embodiment of the present invention. This glove 600 includes nine components, including each of the finger components 610, 612, 614, and 616, the thumb component 618, three palm components 204, 206, and 207, and the wrist component 602. Palm component 507 is referred to as a three-fingered palm since it is attached to only three finger components 612, 614, and 616 (ring, middle, and first). The presence of palm component 607 permits an ergonomic enhancement to the glove by creating a pinky 610 component that is dropped (that is, a “dropped pinky”) as compared to the rest of the fingers. Palm component 606 is a four-fingered palm since it attaches to the pinky 610 and the three-fingered palm component 607. The wrist component contains courses of a colored yarn 620, whose color is chosen to be indicative of the glove size. The wrist component also has a ravel-resistant edge 622.

The finger crotch areas 650, 652, 654 and 656 are reinforced with overlapping courses (e.g., three courses) to strengthen the finger crotches as well as provide a barrier to coating material, if the glove is to be coated. Other areas may also be reinforced by overlapping courses such as the edge 622 to provide cuff durability in donning and doffing, finger tips to provide additional durability and abrasion resistance, and so on.

Glove 600 can be knit on a programmable knitting machine to create gloves having variable stitch to achieve an overall shape that accommodates variations in size and shape of individual fingers and hands. These gloves also have zones that are enhanced with different stitch sizes to permit stretch in the areas of the knuckles, which are called high stress zones, as well as reinforced regions having overlapping courses. Glove 600 can be made, for example, according to the exemplary specifications provided in Table 2, where use of one main yarn is indicated with the addition of a colored yarn at the end of the wrist and a heat fusible yarn subsequent to the colored yarn that prevents unraveling. Each of the components is indicated in accordance with FIG. 6. Note that the courses begin with 1 for each component, a plurality of courses creates a section within the component. The stitch setup here shows a number, which indicates how deep the knitting needle penetrates. A lower number indicates less needle penetration and a tighter stitch, while a larger number indicates that the needle penetrates deeper and creates a looser stitch. For example, in component 610, which is the pinky finger, courses 1-47 and 69-82 both have a knitting needle penetration depth of 33, courses 48-50 and 67-68 both have a knitting needle penetration depth of 18, and courses 51-66 have a knitting needle penetration depth of 40. This means that courses 48-50 and 67-68 are more tightly knit than courses 1-47 and 69-82, which in turn are tighter than courses 51-66. Looked at another way, courses 51-66 are the loosest knit of the component corresponding to the second knuckle of the pinky finger to permit ease of movement. The combination of three stitch sizes within a component permits the creation of high stress zones that permit extra stretch where needed during wearing of the glove. Tension of the yarns is kept relatively constant during stitching. High stress zones are similarly provided in components 612, 614, 616, 618, and 606.

In palm component 604, the stitches vary linearly from 28 to 18 along courses 1-96. In this way, the palm component 604 becomes more tightly knit as it approaches the wrist component 602.

In wrist component 602, an additional elastic yarn is weft-inserted relative to the main yarn. The wrist component has a constant stitch size with the main yarn for courses 1-68, and then for courses 69-90, the yarn is changed to a colored size-indicating yarn 620 having a stitch size of 15. Generally, the colored yarn is a polyester and elastic composite yarn. The wrist component is then finished with an edge formed by a heat fusible yarn 622, which generally comprises elastic, polyester, and low melt polyethylene.

To generate the reinforced regions, the following steps are performed.

1) In the components 610, 612, 614, 616 and 618, the plait feeder is activated to twist the last courses of the finger components, in order to reinforce the finger crotch areas 650, 652, 654, 656. 2) In areas 606 and 607, the plait feeder is activated to twist the first course of the upper palm area to reinforce the crotch areas 650, 652, 654 and 656. 3) When activated, the plait feeder adds an extra thread (Yarn U3 in Table 2) into the main thread of the liner, creating the overlapping yarn and a reinforcement in the fingers crotch area 650, 652, 654 and 656. 4) In the finger crotch areas 650, 652, 654 and 656, an extra knot is added in the finger crotch area and twisted using the knitting machine default finger crotch area knot by using extra needles from the needle bed.

TABLE 2 Knitting Component Total Stitch Pattern Courses (FIG. 6) Courses Courses Setup U3 Start Stop Yarn 610 80  1-47 33 Main 48-50 31 51-66 35 67-68 31 69-80 33 2 1-60 U3 1 61-82  U3 612 114  1-61 33 Main 62-64 31 65-80 35 81-82 31  83-114 33 2 1-92 U3 1 93-110 U3 614 118  1-69 33 Main 70-72 31 73-88 35 89-90 31  91-118 33 2 1-96 U3 1 97-118 U3 616 106  1-57 33 Main 58-60 31 61-76 35 77-78 31  79-106 33 2 1-88 U3 1 89-106 U3 607 8 1-8 28 Main 1 1-6  U3 2 7-10 U3 606 52  1-27 33 Main 28-30 31 31-50 35 51-52 31 2 1-25 U3 1 27-52  U3 618 84  1-39 33 Main 40-42 31 43-58 35 59-60 31 61-84 33 2 1-62 U3 1 63-88  U3 604 96  1-96 18 Main 1 1-6  U3 2 7-52 U3 602 100  1-68 32 Main +  69-100 30 Elastic Color Yarn Edge 2 1-2 28 Heat Fusible Yarn

The specification in Table 2 can be used on a SFG knitting machine available from Shima Seiki Mfg., Ltd. based in Wakayama, Japan to create a size 9 glove. The information for the stitch setup and the number of courses is entered into the knitting machine's operation system using a keypad and LED display. Adjustments can be made to the specifications in Table 2 to create gloves of different sizes. The gloves can be knit from different compositions of yarn, including cotton, nylon fibers, water-soluble fibers, such as polyvinyl alcohol, or other fibers that can be used on a knitting machine, such as polyester or high-strength synthetic and/or cut-resistant fibers, such as aramid & para-aramid, polyethylene & ultra high molecular weight polyethylene, and liquid crystal polymer. The yarns used to knit the gloves can be spun yarns, textured filament yarns, or multi-component composite yarns. Gloves according to the present invention are suitable for comfortably handling tools, fine instruments, and small mechanical parts where dexterity is needed.

Table 2 provides stitch setups for the needles (in one embodiment, both back and front beds use the same setup). In some designs, it may be desirable to provide the reinforced regions in fewer than all or none of components 510, 512, 514, 516, 518, and 506.

Table 2 shows: each component 610, 612, 614, 616, 618, 607, 606, 604, 602, 620, 622; the total number courses to create each component; the specific courses and needle depth used in each course (i.e., stitch dimension); the additional pattern added for reinforcement (pattern U3 using an additional yarn); the courses in the reinforcement pattern; and the yarn used in each course (e.g., main yarn and/or the additional reinforcement yarn). Using this specification, after each component 610, 612, 614, 616, 618, 607, 606 and 604, the additional yarn feeder is activated and pattern U3 is utilized to create a reinforced region in the appropriate location.

Although only a few exemplary embodiments of the present invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. For example, the number of sections of the glove can be increased or decreased to adjust the fit of the glove without departing from the spirit of the present invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims.

The foregoing description of embodiments of the invention comprises a number of elements, devices, machines, components and/or assemblies that perform various functions as described. These elements, devices, machines, components and/or assemblies are exemplary implementations of means for performing their respectively described functions.

While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. 

1. A knitted glove comprising: a plurality of glove components wherein at least one section of at least one of the components in the plurality of components comprises two yarns knitted simultaneously forming a plated structure; and at least one reinforced region formed on the glove having at least three stitch courses.
 2. The knitted glove of claim 1 wherein the plurality of glove components comprises: four finger components with each having at least two separate knitted sections; a thumb component having at least two separated knitted sections; two palm components with each having at least two separate knitted sections; and a wrist component having at least one knitted section.
 3. The knitted glove of claim 2 wherein the interconnection of finger components and finger to thumb components forms a crotch area in which the at least one reinforced region is formed.
 4. The knitted glove of claim 3 further comprising a coating over at least a portion of the four finger components, thumb component and two palm components, where the coating does not penetrate through the at least one reinforced region.
 5. The knitted glove of claim 1 wherein at least a portion of at least one component is knitted using a single yarn and the reinforced regions is knitted using at least one additional yarn.
 6. The knitted glove of claim 1 wherein the plated structure comprises at least one glove section adjacent to a finger crotch area.
 7. The knitted glove of claim 1 wherein the plated structure comprises at least one of 4, 5 or six stitch courses.
 8. The knitted glove of claim 1 wherein the at least one reinforced region is located in a crotch area.
 9. A knitted glove comprising: a plurality of glove components wherein at least one section of at least one of the components in the plurality of components comprises two yarns knitted simultaneously forming a plated structure, where the plurality of components comprises: four finger components with each having at least two separate knitted sections; a thumb component having at least two separated knitted sections; two palm components with each having at least two separate knitted sections; and a wrist component having at least one knitted section; and a plurality of reinforced regions formed on the glove having at least three stitch courses, where at least one reinforced region of the plurality of reinforced regions is formed at a finger crotch area formed by an interconnection of finger components or finger to thumb components.
 10. The knitted glove of claim 9 further comprising a coating over at least a portion of the four finger components, thumb component and two palm components, where the coating does not penetrate through the at least one reinforced region.
 11. The knitted glove of claim 9 wherein at least a portion of at least one component is knitted using a single yarn and the reinforced region is knitted using at least one additional yarn.
 12. The knitted glove of claim 9 wherein the plated structure comprises at least one glove section adjacent to the finger crotch area.
 13. The knitted glove of claim 9 wherein the plated structure comprises at least one of 4, 5 or six stitch courses.
 14. A method of making a knitted glove comprising: knitting a plurality of components of a glove wherein at least one section of at least one of the components comprises two yarns knitted simultaneously forming a plated structure; and knitting at least one reinforced region on the glove having at least three stitch courses.
 15. The method of claim 14 wherein knitting a plurality of components comprises: knitting four finger components with each having at least two separate knitted sections; knitting a thumb component having at least two separated knitted sections; knitting two palm components with each having at least two separate knitted sections; and knitting a wrist component having at least one knitted section.
 16. The method of claim 15 wherein the plated structure is in at least one glove section adjacent to a finger crotch area formed at the interconnection of finger components or thumb to finger components.
 17. The method of claim 14 wherein the plated structure comprises at least one of 4, 5 or 6 stitch courses.
 18. The method of claim 14 further comprising: forming a coating on at least a portion of at least one component, where the coating does not penetrate through the reinforced region.
 19. The method of claim 18 wherein the coating is at least one of natural latex, nitrile or polyurethane. 